Electrical connector system with internal spring component and applications thereof

ABSTRACT

An electrical connector system for electrically and mechanically connecting with a component in a motor vehicle is disclosed. The connector system includes a motor vehicle component and a male connector assembly with a male housing that receives a male terminal. This terminal includes a receiver and side walls with a contact arm that extends across an aperture in the side wall. An internal spring member with at least one spring arm resides within the male terminal receiver. A female connector assembly includes a female terminal with a receptacle that receives both the male terminal and the spring member. A female housing receives the female terminal and an extent of the male connector assembly. When the connector system moves from the partially assembled state to a connected position for connection of the vehicle component, the male connector assembly is inserted into female housing, the contact arm is brought into sliding engagement with an angled internal segment of the female housing, and the contact arm is inwardly displaced as the contact arm slidingly engages with the angled internal segment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application is a Continuation of International Patent Application No. PCT/US2019/036127, filed Jun. 7, 2019, which claims the benefit of U.S. Provisional Patent Application No. 62/681,973, filed on Jun. 7, 2018. The disclosures set forth in the referenced applications are incorporated herein by reference in their entireties.

FIELD OF DISCLOSURE

The present disclosure relates to electrical connectors, and, in particular, to an electrical connector system having a spring actuated electrical connector assembly and their applications thereof. Specifically, the present disclosure relates to an electrical connector system for use in motor vehicles, including passenger and commercial vehicles, in high-power, high-current and/or high-voltage applications where connector assemblies are essential to provide mechanical and electrical connectivity while meeting strict industry standards and production requirements.

BACKGROUND

Over the past several decades, the number of electrical components used in automobiles, and other on-road and off-road vehicles such as pick-up trucks, commercial trucks, semi-trucks, motorcycles, all-terrain vehicles, and sports utility vehicles (collectively “motor vehicles”) has increased dramatically. Electrical components are used in motor vehicles for a variety of reasons, including but not limited to, monitoring, improving and/or controlling vehicle performance, emissions, safety and creature comforts to the occupants of the motor vehicles. These electrical components are mechanically and electrically connected within the motor vehicle by conventional connector assemblies, which consist of an eyelet and a threaded fastener. Considerable time, resources, and energy have been expended to develop connector assemblies that meet the varied needs and complexities of the motor vehicles market; however, conventional connector assemblies suffer from a variety of shortcomings.

Motor vehicles are challenging electrical environments for both the electrical components and the connector assemblies due to a number of conditions, including but not limited to, space constraints that make initial installation difficult, harsh weather conditions, vibration, heat loads, and longevity, all of which can lead to component and/or connector failure. For example, incorrectly installed connectors, which typically occur in the assembly plant, and dislodged connectors, which typically occur in the field, are two significant failure modes for the electrical components and motor vehicles. Each of these failure modes lead to significant repair and warranty costs. For example, the combined annual accrual for warranty by all of the automotive manufacturers and their direct suppliers is estimated at between $50 billion and $150 billion, worldwide.

A more appropriate, a robust connector assembly must be impervious to harsh operating conditions, prolonged vibration and excessive heat, especially heat loads that accumulate “under the hood” of the vehicle. In order to create a robust solution, many companies have designed variations of spring-loaded connectors, which have a feature that retains the connector in place. Such spring-actuated connectors typically have some indication to show that they are fully inserted. Sometimes, the spring-actuated feature on the connector is made from plastic. Other times, the spring-actuated feature on the connector is fabricated from spring steel. Unfortunately, although the more recent connectors are an improvement over dated connectors using an eyelet and threaded connector, there are still far too many failures.

Part of the reason that spring-actuated connector assemblies fail in motor vehicle applications is because of the design of the assembly—namely that the spring element, such as a tab, is located on the periphery of the connector. By placing the spring tab on the exterior surface of the connector, manufacturers attempt to make engagement of the assembly's components obvious to the worker assembling the part in the factory. Unfortunately, for both plastic and metal, the increased temperatures of an automotive environment make a peripheral spring prone to premature failure. It is not uncommon for the engine compartment of a motor vehicle to reach or exceed 100° C., with individual components of a motor vehicle engine reaching or exceeding 180° C. At 100° C., most plastics start to plasticize, reducing the retention force of the peripheral spring-actuated element. At 100° C., the thermal expansion of the spring steel will reduce the retention force of a peripheral spring-actuated connector. Also, with respect to spring-actuated features formed from spring steel is the effect of residual material memory inherent in the spring steel as the spring steel is thermally cycled on a repeated basis between high and low temperatures. After many temperature cycles, the spring steel will begin to return to its original, pre-formed shape, which reduces the spring-actuated element's retention force with other components of the connector assembly. This behavior makes the conventional connector assembly susceptible to vibration and failure, each of which significantly reduce the performance and reliability of conventional connectors. For these and many other reasons, the motor vehicle industry needs a more reliable connector system that is low-cost, vibration-resistant, temperature-resistant, and better overall electrical and mechanical performance.

There is clearly a market demand for a mechanically simple, lightweight, inexpensive, vibration-resistant, temperature-resistant, and robust electrical connector system for vehicles. The description provided in the background section should not be assumed to be prior art merely because it is mentioned in or associated with the background section. The background section may include information that describes one or more aspects of the subject technology.

SUMMARY

The present disclosure relates to a spring-actuated electrical connector system, which has a spring actuated electrical connector assembly residing within an external housing assembly. The electrical connector system is primarily intended for use in motor vehicles, including passenger and commercial vehicles, in high-power, and/or high-voltage applications where connector assemblies are essential to meet industry standards and production requirements. The electrical connector system can also be used in military vehicles, such as tanks, personnel carriers and trucks, and marine applications, such as pleasure boats and sailing yachts, or telecommunications hardware, such as server.

According to an aspect of the present disclosure, the system includes a male connector assembly and a female connector assembly. Both the male and female connector assemblies have a housing, which contains a terminal. The male terminal assembly is designed and configured to fit within the female terminal, which forms both a mechanical and electrical connection between these terminals. Specifically, the male terminal assembly includes an internal spring actuator or spring member, which is designed to interact with an extent of the male terminal to ensure that a proper connection is created between the male terminal and female terminal. More specifically, the female terminal forms a receiver that is configured to receive an extent of the male terminal assembly. The male terminal assembly has a male terminal body, which includes a plurality of contact arms. A spring member is nested inside the male terminal body. The spring member resists inward deflection and applies outwardly directed force on the contact arms thereby creating a positive connection and retention force. Unlike other prior art connection systems, the connection between the male terminal and the female terminal become stronger when the connector system experiences elevated temperatures and electrical power.

In one embodiment, the female terminal has a tubular configuration which is fabricated from a sheet of highly conductive copper. The highly conductive copper can be C151 or C110. One side of the sheet of highly conductive copper can be pre-plated with silver, tin, or top tin, such that the inner surface of the tubular member may be plated. The male terminal assembly includes a male terminal body and a spring member. The male terminal body has a plurality of contact arms. The four arms can be placed at 90° increments, meaning that each contact arm has one arm directly opposing side wall of the female terminal. Each contact arm has a thickness, a termination end, and a planar surface with a length and a width.

A spring member is configured to be nested inside the male terminal body. The spring member has spring arms, a middle section, and a rear wall or base. The spring arms are connected to middle or base section. The spring arms have a termination end, a thickness, and a planar surface with a length and width. In the illustrated embodiments, the spring member has the same number of spring arms as the contact element has contact arms. In the illustrated embodiment, the spring arms can be mapped, one-to-one, with the contact arms. The spring arms are dimensioned so that the termination end of the associated contact arm contacts the planar surface of the spring arm. The spring arms of the illustrated embodiments are even in number, symmetrical, and evenly spaced.

The male terminal fits inside the tubular member of the female terminal such that the contact arms contact the inner surface of the tubular member. The spring arms help ensure that the contact arms create an electrical connection with the tubular member. The termination end of the contact arm meets the planar surface of the spring arm, forcing the contact arm to form a substantially perpendicular or at least an obtuse angle with respect to the outer surface of the spring arm. In the illustrated embodiments of the present disclosure, although not required, the tubular member has a symmetrical cross-section.

Other aspects and advantages of the present disclosure will become apparent upon consideration of the following detailed description and the attached drawings wherein like numerals designate like structures throughout the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide further understanding and are incorporated in and constitute a part of this specification, illustrate disclosed embodiments and together with the description serve to explain the principles of the disclosed embodiments. In the drawings:

FIG. 1 is an isometric view of a first embodiment of a connector system having a male connector assembly and a female connector assembly;

FIG. 2 is an exploded isometric view of the connector system shown in FIG. 1;

FIG. 3 is an isometric view of the male connector assembly shown in FIG. 1;

FIG. 4 is an exploded view of the male connector assembly shown in FIG. 2, wherein the male connector assembly has a male housing and a male terminal assembly;

FIG. 5 is a frontal isometric view of the male terminal assembly shown in FIGS. 2 and 4, wherein a spring member is separated from a male terminal;

FIG. 6 is a frontal isometric view of the male terminal assembly shown in FIGS. 2 and 4, wherein the spring member is positioned within the male terminal receiver;

FIG. 7 is a right side view of the male connector assembly shown in FIG. 3, wherein the male locking member is separated from the male housing;

FIG. 8 is an isometric cross-sectional view of the male connector assembly shown in FIG. 7, taken along the 8-8 line of FIG. 7;

FIG. 9 is a zoomed in view of area A shown in FIG. 8;

FIG. 10 is a right side view of the male connector assembly shown in FIG. 3, wherein the male locking member is engaged with the male housing;

FIG. 11 is an isometric cross-sectional view of the male connector assembly shown in FIG. 10, taken along the 11-11 line of FIG. 10;

FIG. 12 is a zoomed in view of area B shown in FIG. 11;

FIG. 13 is an exploded view of the female connector assembly shown in FIG. 2, wherein the female connector assembly has a female housing and a female terminal;

FIG. 14 is a right side view of the female connector assembly shown in FIG. 13, wherein the female locking member is separated from the female connector assembly;

FIG. 15 is a right side view of the female connector assembly shown in FIG. 13, wherein the female locking member is partially engaged with the female housing and the female terminal is not seated within the female housing;

FIG. 16 is an isometric cross-sectional view of the female connector assembly shown in FIG. 15, taken along the 16-16 line of FIG. 15;

FIG. 17 is a zoomed in view of area C shown in FIG. 16;

FIG. 18 is a right side view of the female connector assembly shown in FIG. 13, wherein the female locking member is partially engaged with the female housing and the female terminal is not seated within the female housing;

FIG. 19 is an isometric cross-sectional view of the female connector assembly shown in FIG. 18, taken along the 19-19 line of FIG. 18;

FIG. 20 is a zoomed in view of area D shown in FIG. 19;

FIG. 21 is a right side view of the female connector assembly shown in FIG. 13, wherein the female locking member is partially engaged with the female housing and the female terminal is seated within the female housing;

FIG. 22 is an isometric cross-sectional view of the female connector assembly shown in FIG. 21, taken along the 22-22 line of FIG. 21;

FIG. 23 is a zoomed in view of area E shown in FIG. 21;

FIG. 24 is a right side view of the female connector assembly shown in FIG. 13, wherein the female locking member is partially engaged with the female housing and the female terminal is seated within the female housing;

FIG. 25 is an isometric cross-sectional view of the female connector assembly shown in FIG. 24, taken along the 25-25 line of FIG. 24;

FIG. 26 is a zoomed in view of area F shown in FIG. 25;

FIG. 27 is a right side view of the female connector assembly shown in FIG. 13, wherein the female locking member is engaged and the female terminal is seated within the female housing;

FIG. 28 is an isometric cross-sectional view of the female connector assembly shown in FIG. 27, taken along the 28-28 line of FIG. 27;

FIG. 29 is a zoomed in view of area G shown in FIG. 28;

FIG. 30 is a right side view of the connector system shown in FIG. 1, wherein the male connector assembly is disconnected from the female connector assembly and the CPA is disengaged from the connector system;

FIG. 31 is a cross-sectional view of the connector system shown in FIG. 30, taken along the 31-31 line of FIG. 30;

FIG. 32 is a zoomed in view of area H shown in FIG. 31;

FIG. 33 is a right side view of the connector system shown in FIG. 1, wherein the connector system is in an intermediate position and the CPA is partially engaged with the connector system;

FIG. 34 is a cross-sectional view of the connector system shown in FIG. 33, taken along the 34-34 line of FIG. 33;

FIG. 35 is a zoomed in view of area I shown in FIG. 34;

FIG. 36 is a right side view of the connector system shown in FIG. 1, wherein the male connector assembly is connected to the female connector assembly and the CPA is engaged with the connector system;

FIG. 37 is a cross-sectional view of the connector system shown in FIG. 36, taken along the 37-37 line of FIG. 36;

FIG. 38 is a zoomed in view of area J shown in FIG. 37;

FIG. 39 is a top side view of the connector system shown in FIG. 1, wherein the connector system is in an intermediate position and the CPA is disengaged from the connector system;

FIG. 40 is a cross-sectional view of the connector system shown in FIG. 39, taken along the 40-40 line of FIG. 39;

FIG. 41 is a zoomed in view of area K shown in FIG. 39;

FIG. 42 is a top side view of the connector system shown in FIG. 1, wherein the male connector assembly is connected to the female connector assembly and the CPA is partially engaged with the connector system;

FIG. 43 is a cross-sectional view of the connector system shown in FIG. 42, taken along the 43-43 line of FIG. 42;

FIG. 44 is a zoomed in view of area L shown in FIG. 43;

FIG. 45 is a top side view of the connector system shown in FIG. 1, wherein the male connector assembly is connected to the female connector assembly and the CPA is engaged with the connector system;

FIG. 46 is a cross-sectional view of the connector system shown in FIG. 42, taken along the 43-43 line of FIG. 42;

FIG. 46A is a zoomed in view of area M shown in FIG. 46;

FIG. 47 is a graph showing the insertion forces associated with the connector assemblies disclosed herein and the connector assemblies disclosed within PCT/US2018/019787;

FIG. 48 is a left side view of the male terminal assembly and the female terminal shown in FIG. 2, wherein the male terminal assembly is connected to the female terminal;

FIG. 49 is a cross-section view of the terminal assembly shown in FIG. 48, taken along the 49-49 line of FIG. 48;

FIG. 50 is a isometric view of an in-line fuse application that includes a second embodiment of a connector system having a male connector assembly and a female connector assembly;

FIG. 51 is an exploded view of the in-line fuse application shown in FIG. 50;

FIG. 52 is a top view of the in-line fuse application shown in FIG. 50;

FIG. 53 is a cross-sectional view of the in-line fuse application shown in FIG. 50, taken along the 53-53 line of FIG. 52;

FIG. 54 is a isometric view of an isometric view of a first DC-DC converter application that includes a connector system having a male connector assembly and a female connector assembly;

FIG. 55 is a isometric view of an isometric view of a second DC-DC converter application that includes a connector system having a male connector assembly and a female connector assembly;

FIG. 56 is a isometric view of an isometric view of a third DC-DC converter application that includes a connector system having a male connector assembly and a female connector assembly;

FIG. 57 is a isometric view of an isometric view of a fourth DC-DC converter application that includes a connector system having a male connector assembly and a female connector assembly;

FIG. 58 is a isometric view of an isometric view of a fifth DC-DC converter application that includes a connector system having a male connector assembly and a female connector assembly;

FIG. 59 is a isometric view of an isometric view of a sixth DC-DC converter application that includes a connector system having a male connector assembly and a female connector assembly;

FIG. 60 is a isometric view of an isometric view of a battery pack application that includes a connector system having a male connector assembly and a female connector assembly;

FIG. 61 is a isometric view of an isometric view of a DC-DC converter application that includes a connector system having a male connector assembly and a female connector assembly;

FIG. 62 is an isometric view of an isometric view of a fuse box application that includes a connector system having a male connector assembly and a female connector assembly.

FIG. 63 is a simplified electrical wiring diagram of a motor vehicle that includes multiple connector systems.

In one or more implementations, not all of the depicted components in each figure may be required, and one or more implementations may include additional components not shown in a figure. Variations in the arrangement and type of the components may be made without departing from the scope of the subject disclosure. Additional components, different components, or fewer components may be utilized within the scope of the subject disclosure. Further, it should be understood components and/or features of one embodiment may be utilized in addition to or in replace of components and/or features contained within another embodiment without departing from the scope of the subject disclosure.

DETAILED DESCRIPTION

The detailed description set forth below is intended as a description of various implementations and is not intended to represent the only implementations in which the subject technology may be practiced. As those skilled in the art would realize, the described implementations may be modified in various ways, all without departing from the scope of the present disclosure. Accordingly, the drawings and description are to be regarded as illustrative and not restrictive.

The Figures show a connector system 100, which is designed to mechanically and electrically couple a device (e.g., radiator fan, heated seat, power distribution component, or another current drawing component) to a power source (e.g., alternator, battery, or power distribution component). The connector system 100 may be used in an electrical system, which may be contained within an airplane, the motor vehicle, a military vehicle (e.g., tank, personnel carrier, heavy-duty truck, and troop transporter), a bus, a locomotive, a tractor, a boat, a submarine, a battery pack, a 24-48 volt system, in a high-power application, in a high-current application, in a high-voltage applications, or in another other application where connector assemblies are essential to meet industry standards and production requirements. Specific applications within the above general application arears include, but are not limited to, power distribution junction box, alternator, starter solenoid, motor (e.g., traction motor), starter generator, power electronics (e.g., inverter, DC-DC converter (e.g., 48 volts to 24 volts), power supply, battery charger), jumper cables, connections required for power cables, fuses, buss bars, grounds, relays, battery packs (e.g., 12 volts, 24 volts, 48 volts), on board chargers, charging ports, cooling systems, or any combination of these applications. In addition to the benefits described within PCT/US2019/036010 and PCT/US2019/036070, the benefits of using the connector system 100 in these applications include a reduction in: labor cost (e.g., does not require torqueing, checking, and re-torqueing), cost of the parts to make the connections with the environment, failures, replacement parts, size, weight, along with other reductions.

Referring to the Figures, including a “90 degree” embodiment in FIGS. 1-49, the connector system 100 is comprised of a male connector assembly 200 and a female connector assembly 600. The male connector assembly 200 includes the male housing assembly 220 that encases at least a first substantial extent of a male terminal assembly 430. The female connector assembly 600 includes a female housing 620 with receptacle 653. The female housing 620 is configured to encase a first extent of the female terminal 800. The male housing assembly 220 is designed to: (i) facilitate the coupling of the male terminal assembly 430 with an extent of the female terminal 800, (ii) minimize the chance that male terminal assembly 430 accidentally makes electrical contact with another device or component (e.g., structures contained within the engine compartment of a vehicle, such as the frame or body of the vehicle), and (iii) meet industry standards, such as USCAR specifications. The male housing assembly 220 is typically formed from a material (e.g., polymer, such as plastic or nylon) that is non-conductive using an injection molding or over molding process. Thus, the housing 220 is capable of isolating electrical current that is configured to flow between the male terminal assembly 430 and other components or structures. It should be understood that the male housing assembly 220 does not fully encase the male terminal assembly 430 because at least a second extent of the male terminal assembly 430 must be capable of making contact with an extent of the female terminal 800 to enable current to flow between the male connector assembly 430 and the female terminal 800. As shown in FIG. 51, the male connector assembly 200 may also include a cable strain relief component 530, a connector position assurance (CPA) assembly that includes a CPA component 350, and/or a lead or wire 590. The CPA component 350 is described in greater detail below, but overall the CPA assembly is generally designed to enable the connector system 100 to meet USCAR Specifications, including USCAR-12, USCAR-25, and USCAR-2. The cable strain relief component 530, CPA assembly, and wire 590 may be omitted completely or replaced with different components. For example, the cable strain relief component 530 and the wire 590 may be replaced in an embodiment where the male terminal assembly 430 is directly coupled or integrally formed with a device. Also, in an alternative embodiment, just the cable strain relief component 530 may be omitted due to the configuration (e.g., length, rigidity, positioning, or etc.) of the wire 590.

As shown in the Figures, the female housing 620 is considerably larger than the male housing assembly 220 and is configured to receive a substantial extent of the male housing assembly 220. Like the male housing assembly 220, the female housing 620 is designed to: (i) facilitate the coupling of the male terminal assembly 430 with a female terminal 800, (ii) minimize the chance that female terminal 800 accidentally makes electrical contact with another device or structure, and (iii) meet industry standards, such as USCAR specifications. Accordingly, the female housing 620 is typically formed from a material (e.g., polymer, such as plastic or nylon) that is non-conductive using an injection molding or over molding process. Thus, the housing 620 is capable of isolating electrical current that is configured to flow through between the female terminal 800 and other structures. It should be understood that the female housing 620 does not fully encase the female terminal 800 because at least a second extent of the female terminal 800 must be capable of making contact with the male terminal assembly 620 to enable current to flow between the female connector assembly 600 and the male connector assembly 200. The female connector assembly 600 may also include a cable retainer 530 and a wire 100. The cable strain relief component 530 and wire 590 are optional components that may be omitted completely or replaced with different components. For example, the cable strain relief component 530 and the wire 590 may be completely replaced in an embodiment where the female terminal 800 is fixed to a device. Also, in an alternative embodiment, just the cable strain relief component 530 may be omitted due to the configuration (e.g., length, rigidity, positioning, or etc.) of the lead or wire 590.

FIGS. 1-12 and 30-49 provide various views of the male connector assembly 200. The male connector assembly 200 includes: (i) a male housing assembly 220, (ii) a male terminal assembly 430, (iii) a male locking member 300, and (iv) a lead or wire 590. The male housing assembly 220 includes the front male housing 224 and rear male housing 280. Both the front male housing 224 and the rear male housing 280 have complex geometries with a number of cooperatively positioned and dimensioned recesses, projections, and openings therethrough to allow for coupling of the housing 224, 280. In particular, the front male housing 224 has a body 226, a male CPA component 352, and a terminal receiver 260. The body 226 includes an arrangement of side walls 228 a-228 c and a top wall 236. The arrangement of side walls 228 a-228 c form a “U-shaped” receiver 230 that is configured to receive an extent of the male terminal assembly 230 and the wire 590 (see FIGS. 3, 7-12, and 30-47). Two of the side walls 228 a, 228 c of the front male housing 224 include a first part 232 of a housing coupling means 222, which in the exemplary embodiment is a plurality of integrally formed housing coupling projections 232. In particular, side walls 228 a, 228 c each include two formed housing coupling projections 232. However, in other embodiments, more (e.g., four or six) or fewer (e.g., one) formed housing coupling projections 232 may be utilized.

Side walls 228 a, 228 c also include a male locking means 256, which in this exemplary embodiment includes a plurality of locking member projections 234 a, 234 b that are configured to interact with an first extent 310 of the male locking member 300 to secure the male terminal assembly 340 within the male housing assembly 220. Each of the locking member projections 234 a, 234 b will be discussed in greater detail in connection with FIGS. 7-12. It should be understood that the male locking means 256 may include a different arrangement, combination, or number of components. For example, the side walls 228 a, 228 c may include a recess that interacts with a projection that is formed on the male locking member 300. In further embodiments, male locking means 256 may include structures that utilize magnetic forces, spring forces, material biasing forces or a combination of these forces.

Referring to 3-4 and 10, the top wall 236 of the front male housing 224 is integrally formed with the side walls 228 a-228 c. Specifically, the top wall 236 is connected to each of the side walls 228 a-228 c and resides substantially perpendicular to the side walls 228 a-228 c. The top wall 236 acts as a cap to the body 226 in order to close off the upper extent of the male housing assembly 220. As shown in FIG. 7, the top wall 236 includes a locking member opening 238 configured to receive an extent of the male locking member 300, when the male locking member 300 is secured to the male housing assembly 220. The top wall 236 also includes an integrally formed male CPA component 352. The male CPA component 352 includes (i) a elastically deformable CPA structure 354 and (ii) a elastically non-deformable CPA structure 356. The deformable CPA structure 354 and the non-deformable CPA structure 356 are discussed in greater detail in connection with FIGS. 39-47.

As shown in FIGS. 3, 4, and 7-12, the male terminal receiver 260 is formed from an arrangement of terminal receiver side walls 262 a-262 d and a terminal receiver front wall 264. The side walls 262 a-262 d in combination with the front wall 264 forms a bowl shaped receiver 266. The receiver 266 is configured to snugly receive a majority of the male terminal assembly 430 when it is seated within the male housing assembly 220. This configuration provides additional rigidity to the male terminal assembly 430 and limits the exposed amount of the male terminal assembly 430. However, the entire male terminal assembly 430 is not enclosed within the housing 224 because then the male terminal assembly 430 would then be prevented from contacting the female terminal 800. Thus, to facilitate the coupling of the male terminal 430 to the female terminal 800, the side walls 262 a-262 d each have male terminal openings 268 a-268 d therethrough. The male terminal openings 268 a-268 d are disposed through an intermediate portion of the side walls 262 a-262 d and are configured to permit an extent of the male terminal assembly 430 to extend through the side walls 262 a-262 d to enable the male terminal assembly 430 to contact the female terminal 800. The male terminal openings 268 a-268 d may be configured such that they are not large enough to accept insertion of an assembler's finger, a test probe, or another foreign body.

It should be understood that the further the extent of the male terminal assembly 430 extends past the outer surface 274, there is a greater chance that this extent will accidentally come into contact within a foreign body. Thus, the extent of the male terminal assembly 430 that extends past the outer surface 274 needs to balance the ability to form a proper connection with the female terminal 800. The design disclosed herein balances these factors and the extent of the male terminal assembly 430 extends beyond the outer surface 274 by less than 2 mm and preferably less than 0.5 mm. In comparison to the length of the male terminal openings 268 a-268 d, the extent of the male terminal assembly 430 extends beyond the outer surface 274 is less than 8% of the length and preferably less than 4% of the length.

In other embodiments, the configuration of the terminal receiver 260 and the male terminal openings 268 a-268 d may be different to accommodate a different male terminal assembly 430. For example, the terminal receiver 260 may have an elongated rectangular configuration to accept the male terminal assemblies described within FIGS. 59-68 of PCT patent application PCT/US2019/036010. Also, in this embodiment from PCT patent application PCT/US2019/036010, the terminal receiver 260 will not have male terminal openings positioned within an intermediate portion of side walls 262 b, 262 d because the side walls 3062 b, 3062 d do not have contact arms 494 a-494 h. Alternatively, the terminal receiver 260 may have a substantially circular configuration to accept the male terminal assemblies described within FIGS. 87-96 of PCT patent application PCT/US2019/036010. In further embodiments, the terminal receiver 260 may be triangular, hexagonal or type of polygonal.

As shown in FIGS. 2, and 4, the male housing assembly 220 is formed from multiple parts to enable the housing 220 to be disassembled for coupling of the wire to the male terminal 430, inspection and/or servicing. Disassembly is made possible by the housing connection means 222, which may be formed from two separate parts, where a first part or the housing coupling projections 232 is coupled to the front male housing 224 and a second part or a housing coupling receiver 282 is coupled to the rear male housing 280. The plurality of front male coupling projections 232 have a ramped, wedge, or triangular configuration. The housing coupling receiver 282 has a substantially “U-shaped” configuration. To couple the connection means 222, which in turn will couple the rear male housing 280 to the front male housing 224, the assembler will apply a male housing connection force, F_(MC), on the rear male housing 280. This male housing connection force, F_(MC), will cause an extent of at least one of the housing coupling receiver 282 to interact with the associated housing coupling projections 232. The interaction between these components will cause the rear male coupling receiver 282 to elastically deform in a manner that allows the rear male coupling receiver 282 to slide up the ramp of the front male coupling projection 232. Once the assembler has applied enough male housing connection force, F_(MC), to move the rear male coupling receiver 282 past the front male coupling projection 232, the rear male coupling receiver 282 will return to its original or non-deformed state. At this point, at least an extent of the rear male housing 280 is coupled to the front male housing 224 (see FIGS. 3, 7-12, and 30-47). The assembler should then repeat this process for the other connection means 222 to fully connect the rear male housing 280 to the front male housing 224.

To disconnect the front male housing 224 from the rear male housing 280, the assembler will apply a male housing removal force that is orientated in a direction that is away from the front male housing 224 on the rear male coupling receiver 282. This force must be sufficient to elastically deform the rear male coupling receiver 282 enough to allow it to slide rearward past the front male coupling projections 232. In other embodiments, the connection means 222 may include a different arrangement, combination, or number of components. For example, the rear male housing 280 may include the projection that interacts with a receiver that is formed in the front male housing 224. In even further embodiments, the connection means 222 may include structures that utilize magnetic forces, spring forces, material biasing forces or a combination of these forces.

FIGS. 1-4, 7-12, and 30-49 show that the male connector assembly 200 has an “L-shaped” configuration. In other words, an extent of the male terminal assembly 430 is positioned substantially perpendicular to the wire 590. When coupling the male connector assembly 200 to the female connector assembly 600, the assembler will apply a coupling force, F_(C), that is substantially perpendicular to the wire 590 and substantially parallel to an extent of the male terminal assembly 430. As discussed above, the male connector assembly 200 may have other configurations. For example, the overall shape of the male connector assembly 200 may be substantially linear, like the configuration of the female housing 620. In this embodiment, structures and features that are similar to the structures and features described below in connection with the female connector assembly 600 may be utilized and their utilization will allow for the use of a male housing assembly 220 that is not configured to be disassembled. In other embodiments, the overall shape of the male connector assembly 200 may be between linear and L-shaped.

FIGS. 2, 4-6, 8, 11, 31, 34-35, 37-38, 40-41, 43-44, 46-46 a, 48-49, provide various views of the male terminal assembly 430. Specifically, the male terminal assembly 430 includes a spring member 440 a, 440 b and a male terminal 470. The male terminal 470 includes a male terminal body 472 and a male terminal connection member or plate 474. Said male terminal body 472 includes: (i) a first or front male terminal wall 480, (ii) an arrangement of male terminal side walls 482 a-482 d, and (iii) a second or rear male terminal wall 484. The combination of these walls 480, 482 a-482 d forms a male terminal receiver 486. The spring member 440 a, 440 b includes an arrangement of spring member side walls 442 a-442 d and a rear spring wall 444.

Coupling or positioning the spring member 440 a, 440 b within the male terminal assembly 430 occurs across multiple steps or stages. FIG. 5 provides the first embodiment of the male terminal assembly 430 in a disassembled state, S_(D), FIG. 6 provides the first embodiment of the male terminal assembly 430 in a partially assembled state, S_(P), and FIG. 31 or 40 provides the first embodiment of the male terminal assembly 430 in an assembled state, S_(A). The first stage of assembling the male terminal assembly 430 is shown in FIG. 5, where the front male terminal wall 480 is in an open or flat position, P_(O), and the spring member 440 a is separated from the male terminal 470. In this open position, P_(O), the front male terminal wall 480 is substantially co-planar with the male terminal side wall 482 c. This configuration of the male terminal 470 exposes the male terminal receiver 486 and places the male terminal 470 in a state that is ready for receiving the spring member 440 a, 440 b. The second stage of assembling the male terminal assembly 430 is shown in FIG. 6, where the front male terminal wall 480 is in an open or horizontal position, P_(O), and the spring member 440 a, 440 b is positioned within or inserted into the male terminal receiver 486. To reach the inserted state, an insertion force, F_(I), has been applied to the spring member 440 a, 440 b to insert the spring member 440 a, 440 b into the male terminal receiver 486. The insertion force, F_(I), is applied on the spring member 440 a, 440 b until the second or rear male terminal wall 484 is positioned adjacent to the rear spring wall 444, a free end 488 of the male terminal 470 is substantially aligned with a free end 446 of the spring member 440 a, 440 b, and a portion of the male terminal side walls 482 a-482 d are positioned adjacent a portion of the spring member side walls 442 a-442 d.

The third stage of assembling the male terminal assembly 430 is shown in FIG. 31 or 41, where: (i) the front male terminal wall 480 is closed or vertical, P_(CL), and (ii) the spring member 440 a, 440 b is positioned within the male terminal receiver 486. To close the front male terminal wall 480, an upward directed force is applied to the male terminal wall 480 to bend it about its seam to place it adjacent to the side walls 482 a-482 d. After the front male terminal wall 480 is in the proper position, the top edge is coupled (e.g., welded) to the side wall 480 of the male terminal body 472. Here, the closed or vertical, P_(CL), of the front male terminal wall 480 ensures that the spring member 800 is retained within the male terminal 470. It should be understood that in other embodiments, the front male terminal wall 480 may be omitted, may not have an opening 510 there through, may not extend the entire way from side wall 482 a-482 d (e.g., partially extending from any side wall 482 a-482 d), or may be a separate piece that is coupled to both side walls 482 a-482 d.

FIG. 2, 4-6, 8, 11, 31, 34-35, 37-38, 40-41, 43-44, 46-49 show views of two different embodiments of the spring member 440 a, 440 b that are configured to function with the first embodiment of the male terminal 470. Specifically, FIGS. 5-6 show a first embodiment of the spring member 440 a, while FIGS. 2, 4, 8, 11, 31, 34-35, 37-38, 40-41, 43-44, 46-49 show a second embodiment of the spring member 440 b. The primary differences between the first and second embodiments include two alterations to the configuration of the spring members 440 a, 440 b, wherein these alterations include: (i) recess 554 and associated strengthening rib 556 and (ii) the width of the base spring sections 450 a-450 d. As discussed in PCT/US2019/036010, these changes to the configuration of the spring members 440 a, 440 b alter the forces that are associated with the spring 440 a, 440 b. In particular, the spring biasing force, S_(BF), is the amount of force that is applied by the spring member 440 a, 440 b to resist the inward deflection of the free end 446 of the spring member 440 a, 440 b when the male terminal assembly 430 is inserted within the female terminal 800. Specifically, this inward deflection occurs during insertion of the male terminal assembly 430 due to the fact that an extent of an outer surface of the male terminal body 472 is slightly larger than the interior of the female terminal 800. Thus, when the male terminal assembly 430 is inserted into the female terminal 800, the extent of the outer surface is forced towards the center 490 of the male terminal 470. This inward force on the outer surface displaces the free end 446 of the spring member 440 a, 440 b inward (i.e., towards the center 490). The spring member 440 a, 440 b resists this inward displacement by providing a spring biasing force, S_(BF). Also, as discussed within PCT/US2019/036010, the first embodiment of the spring member 440 a has a higher insertion force and thus a larger spring biasing force, S_(BF), in comparison to the second embodiment of the spring member 440 b.

As discussed above, the spring member 440 a, 440 b generally includes: (i) an arrangement of spring member side walls 442 a-442 d and a rear spring wall 444. More specifically, the arrangement of spring member side walls 442 a-442 d each are comprised of: (i) a first or arched spring section 448 a-448 d, (ii) a second spring section, a base spring section, or a middle spring section 450 a-450 d, and (iii) a third section or spring arm 452 a-452 h. The arched spring sections 448 a-448 d extend between the rear spring wall 444 and the base spring sections 450 a-450 d and position the base spring sections 450 a-450 d substantially perpendicular to the rear spring wall 444. In other words, the outer surface of the base spring sections 450 a-450 d is substantially perpendicular to the outer surface of the rear spring wall 444.

The base spring sections 450 a-450 d are positioned between the arched sections 448 a-448 d and the spring arms 452 a-452 h. As shown in FIG. 2, 4-6, 8, 11, 31, 34-35, 37-38, 40-41, 43-44, 46-49, the base spring sections 450 a-450 d are not connected to one another and thus middle section gaps are formed between the base spring sections 450 a-450 d of the spring member 440 a, 440 b. The gaps aid in omnidirectional expansion of the spring arms 452 a-452 h, which facilitates the mechanical coupling between the male terminal 470 and the female terminal 800. The spring arms 452 a-452 h extend from the base spring sections 450 a-450 d of the spring member 440 a, 440 b, away from the rear spring wall 444, and terminate at the free end 446. The spring arms 452 a-452 h are generally coplanar with the base spring sections 450 a-450 d and as such the outer surface of the spring arms 452 a-452 h are coplanar with the outer surface of the base spring sections 450 a-450 d. Unlike the spring arm 31 that is disclosed within FIGS. 4-8 of PCT/US2018/019787 the free end 446 of the spring arms 452 a-452 h do not have a curvilinear component. Instead, the spring arms 452 a-452 h have a substantially planar outer surface. This configuration is beneficial because it ensures that the forces associated with the spring 440 a, 440 b are applied substantially perpendicular to the free end 488 of the male terminal body 472. In contrast, the curvilinear components of the spring arm 31 that are disclosed within FIGS. 4-8 of PCT/US2018/019787 do not apply a force in this manner

Like the base spring sections 450 a-450 d, the spring arms 452 a-452 h are not connected to one another. In other words, there are spring arm openings that extend between the spring arms 452 a-452 h. Due to the spring arm openings and the spring finger apertures, the individual spring fingers 452 a-452 h are not connected to one another or connected to a structure other than the base spring sections 450 a-450 d. This configuration allows for omnidirectional of the spring arms 452 a-452 h, which facilitates in the mechanical coupling between the male terminal 470 and the female terminal 800. In other embodiments, the spring arms 452 a-452 h may be coupled to other structures to restrict their omnidirectional expansion. The number and width of individual spring arms 452 a-452 h and openings may vary. In addition, the width of the individual spring arms 452 a-452 h is typically equal to one another; however, in other embodiments one of the spring arms 452 a-452 h may be wider than other spring arms.

The spring member 440 a, 440 b is typically formed from a single piece of material (e.g., metal). Therefore, the spring member 440 a, 440 b is a one-piece spring member 440 a, 440 b or has integrally formed features. In particular, the following features are integrally formed: (i) the rear spring wall 444, (ii) the curvilinear sections 448 a-448 d, (iii) the base spring sections 450 a-450 d, and (iii) the spring finger 452 a-452 h. To integrally form these features, the spring member 440 a, 440 b is typically formed using a die forming process. The die forming process mechanically forces the spring member 440 a, 440 b into shape. As discussed in greater detail below and in PCT/US2019/036010, when the spring member 440 a, 440 b is formed from a flat sheet of metal, installed within the male terminal 472 and connected to the female terminal 800, and is subjected to elevated temperatures, the spring member 440 a, 440 b applies an outwardly directed spring thermal force, S_(TF), on the contact arms 494 a-494 h due in part to the fact that the spring member 440 a, 440 b attempts to return to a flat sheet. However, it should be understood that other types of forming the spring member 440 a, 440 b may be utilized, such as casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the spring member 440 a, 440 b may not be formed from a one-piece or be integrally formed, but instead formed from separate pieces that are welded together.

FIG. 2, 4-6, 8, 11, 31, 34-35, 37-38, 40-41, 43-44, 46-49 show the first embodiment of the male terminal 470. As discussed above, the first embodiment of the male terminal 470 includes the male terminal body 472 and a male terminal connection plate 474. Specifically, the male terminal connection plate 474 is coupled to the male terminal body 472 and is configured to receive an extent of a structure (e.g., lead or wire, as shown in FIG. 2) that connects the male terminal assembly 430 to a device (e.g., an alternator) outside of the connector system 100. The wire 590 is typically welded to the connection plate 474; however, other methods (e.g., forming the wire 590 as a part of the connection plate 474) of connecting the wire 590 to the connection plate 474 are contemplated by this disclosure.

The arrangement of male terminal side walls 482 a-482 d are coupled to one another and generally form a rectangular prism. The arrangement of male terminal side walls 482 a-482 d include: (i) a side wall portion 492 a-492 d, which generally has a “U-shaped” configuration, (ii) contact arms 494 a-494 h, and (iii) a plurality of contact arm openings 496 a-496 l. As best shown in FIGS. 2 and 5-6, the side wall portions 492 a-492 d are substantially planar and have a U-shaped configuration. The U-shaped configuration is formed from three substantially linear segments, wherein a second or intermediate segment 500 a-500 d is coupled on one end to a first or end segment 498 a-498 d and on the other end to a third or opposing end segment 502 a-502 d. The contact arms 494 a-494 h extend: (i) from an extent of the intermediate segment 500 a-500 d of the side wall portion 492 a-492 d, (ii) away from the rear male terminal wall 484, (iii) across an extent of the contact arm openings 496 a-496 l, and (iv) terminate just short of the front male terminal wall 480. This configuration is beneficial over the configuration of the terminals shown in FIGS. 9-15, 18, 21-31, 32, 41-42, 45-46, 48 and 50 in PCT/US2018/019787 because it allows for: (i) can be shorter in overall length, which means less metal material is needed for formation and the male terminal 470 can be installed in narrower, restrictive spaces, (ii) has a higher current carrying capacity, (iii) is easier to assemble, (iv) improved structural rigidity because the contact arms 494 a-494 h are positioned inside of the first male terminal side wall portion 492 a-492 d, (iv) benefits that are disclosed in connection with PCT/US2019/036070, and (v) benefits that are disclosed in connection with PCT/US2019/036010, and (v) other beneficial features that are disclosed herein or can be inferred by one of ordinary skill in the art from this disclosure.

The arrangement of contact arm openings 496 a-496 l are integrally formed with the intermediate portion 500 a-500 d of the male terminal side walls 482 a-482 d. The contact arm openings 496 a-496 l extend along the lateral length of the contact arms 494 a-494 h in order to create a configuration that permits the contact arms 494 a-494 h not to be laterally connected to: (i) another contact arm 494 a-494 h or (ii) a structure other than the extent of the male terminal side wall portion 492 a-492 d to which the contact arms 494 a-494 h are coupled thereto. Additionally, the contact arm openings 496 a-496 l are aligned with the spring arm openings. This configuration of openings forms the same number of spring arms 452 a-452 h as the number of contact arms 494 a-494 h. In other words, FIGS. 5-6 show eight spring arms 452 a-452 h and eight contact arms 494 a-494 h. Additionally, these figures show that the width of the spring arms 452 a-452 h substantially matches the width of the contact arms 494 a-494 h. It should be understood that in other embodiments, the number of spring arms 452 a-452 h may not match the number of contact arms 494 a-494 h. For example, there may be fewer one spring arms 452 a-452 h.

The contact arms 494 a-494 h extend away from the rear male terminal wall 484 at an outward angle. In particular, the outward angle may be between 0.1 degree and 16 degrees between the outer surface of the extent of the male terminal side wall 492 a-492 d and the outer surface of the first extent of the contact arms 494 a-494 h, preferably between 5 degrees and 12 degrees and most preferably between 7 degrees and 8 degrees. This outward angle is shown in multiple figures, but may be best visualized in connection with FIGS. 3-6, 8, 11, 33-34, and 37-38. This configuration allows the contact arms 494 a-494 h to be deflected or displaced inward and towards the center 490 of the male terminal 470 by the female terminal 800, when the male terminal assembly 430 is inserted into the female terminal 800. This inward deflection is best shown in FIGS. 37-38, 43-44, 46-47 and 49 and other figures contained within PCT/US2019/036010 and PCT/US2019/036070. This inward deflection helps ensure that a proper mechanical and electrical connection is created by ensuring that the contact arms 494 a-494 h are placed in contact with the female terminal 800.

As shown in FIGS. 6, 37-38, 40-41, 43, 46 and 49, the terminal ends of the contact arms 494 a-494 h are positioned: (i) within an aperture formed by the U-shaped side wall portions 492 a-492 d, (ii) within the receiver 486, (iii) substantially parallel to the male terminal side wall 492 a-492 d, and (iv) in contact the planar outer surface of the spring arms 452 a-452 h, when the spring member 440 a, 440 b is inserted into the male terminal receiver 486. This configuration is beneficial over the configuration shown in FIGS. 3-8 in PCT/US2018/019787 because the assembler of the male terminal assembly 430 does not have to apply a significant force in order to deform a majority of the contact arms 494 a-494 h outward to accept the spring member 440 a, 440 b. This required deformation can best be shown in FIG. 6 of PCT/US2018/019787 due to the slope of the contact arm 11 and the fact the outer surface of the spring arm 31 and the inner surface of the contact arm 11 are adjacent to one another without a gap formed therebetween. In contrast to FIGS. 3-8 in PCT/US2018/019787, FIGS. 6, 37-38, 40, 43, and 46 of the present application show a gap that is formed between the outer surfaces of the spring member 440 a, 440 b and the inner surface of the contact arms 494 a-494 h. Accordingly, very little force is required to insert the spring member 440 a, 440 b into the receiver 486 due to the fact the assembler does not have to force the contact arms 494 a-494 h to significantly deform during the insertion of the spring 440 a, 440 b.

The male terminal 470 is typically formed from a single piece of material (e.g., metal). Therefore, the male terminal 470 is a one-piece male terminal 470 and has integrally formed features. To integrally form these features, the male terminal 470 is typically formed using a die cutting process. However, it should be understood that other types of forming the male terminal 470 may be utilized, such as casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the male terminal 470 may not be formed from one-piece or be integrally formed, but instead formed from separate pieces that are welded together.

FIGS. 4 and 7-12 show the positioning of the male terminal assembly 430 within the male housing assembly 220. Coupling the male terminal assembly 430 within the male housing assembly 220 occurs across multiple steps or stages. The first step in this process starts with securing the male terminal assembly 430 within the male terminal receiver 260 using a male securing means 239. The securing means 239 in this exemplary embodiment includes a securing arm 240. A first insertion force, F_(I), on the male terminal assembly 430 cause securing arms 240 to interact with the front male terminal wall 480 of the male terminal assembly 430. This interaction will cause the securing arms 240 to elastically deform outward and towards the side walls 228 a, 228 c of the front male housing body 226. Specifically, the securing arms 240 will elastically deform around a securing arm projection 242 that is formed within the side walls 228 a and 228 c (FIG. 9). The deformation around the securing arm projection 242 will cause an extent of the securing arms 240 to be positioned within securing arm gap 244. Positioning an extent of the securing arms 240 within the securing arm gap 244 will allow the male terminal assembly 430 to be inserted into the terminal receiver 260. It should be understood that the assembler must apply a sufficient amount of insertion force, to cause the securing arms 240 to elastically deform. Without applying a sufficient amount of insertion force, F_(I), the assembler will not be able to cause the securing arms 240 to elastically deform; thus, the assembler will not be able to position the male terminal assembly 430 within the male housing assembly 220. Also, it should be understood that the width of the securing arm projection 242, the length the securing arm 240 extends past the securing arm projection 242, the thickness of the securing arm 240, and the material of the securing arm 240 will alter the amount of insertion force, F_(I), that is necessary to couple the male terminal assembly 430 to the male housing assembly 220.

The next step in the process of positioning the male terminal assembly 430 within the male housing assembly 220 occurs when the assembler applies a second insertion force, F_(I), on the male terminal assembly 430 to cause: (i) the front male terminal wall 480 to be positioned against the inner surface 272 of the front wall 264, (ii) the contact arms 494 a-494 h to be positioned within the male terminal openings 268 a-268 d. At this point, the securing arms 240 can return to their original or non-deformed state due to the fact the securing arms 240 can fit into a securing arm receiver 476 that is formed in the rear male terminal wall 484 of the male terminal 470. The return of the securing arms 240 may cause an audible sound (e.g., click) when it moves from the deformed state to the original or non-deformed state. This audible sound will inform the assembler that the male terminal assembly 430 is properly seated within the male housing assembly 220; thus meeting industry standards and/or requirements (e.g., USCAR).

The final step in the process of coupling the male terminal assembly 430 within the male housing assembly 220 occurs when the assembler applies a locking force, F_(L), on the male locking member 300. The application of the locking force, F_(L), on the male locking member 300 will cause a first extent 310 of the male locking member 300 to elastically deform outward in order to overcome the male locking member projections 234 a, 234 b. Meanwhile, the application of the locking force, F_(L), on the male locking member 300 will not cause a second extent 312 of the male locking member 300 to elastically deform in the same manner as the first extent 310. The first extent 310 elastically deforms in a different manner then the second extent 312 due to the configuration of the male housing assembly 220. Specifically, the first extent 310 travels against the outside surface of the side walls 228 a-228 c and must pass over the locking member projections 234 a, 234 b, while the second extent 312 travels against the inside surface of the side walls 228 a-228 c and does not have to pass over any locking member projections 234 a, 234 b.

Once the male locking member 300 has overcome the second male locking member projection 234 b, the first extent 310 of the male locking member 300 will return to its original or non-deformed state. The return of the first extent 310 of the male locking member 300 may cause an audible sound (e.g., click) when it moves from the deformed state to the non-deformed state. This audible sound will inform the assembler that the male locking member 300 is properly connected to the male housing assembly 220; thus meeting industry standards and/or requirements (e.g., USCAR). Additionally, when the male locking member 300 is properly connected to the male housing assembly 220 (see FIG. 12), the second extent 312 is positioned within the securing arm gap 244. Positioning the second extent 312 within the securing arm gap 244 ensures that the male terminal assembly 430 cannot be removed from the male housing assembly 220 without damaging the housing 220 because the securing arms 240 cannot be elastically deform into the securing arm gap 244 as the securing arm gap 244 is occupied by the second extent 312. At this point, the male terminal assembly 430 is properly coupled to the male housing assembly 220. The male locking member 300 may also position an extent (not shown) of the male locking member 300 behind the male terminal assembly 430, when the male locking member 300 is properly connected to the male housing assembly 220. The extent of the male locking member 300 may be similar to the secondary lock 712, which is shown and described in connection with FIGS. 2, 19-20 and 25-29. This additional secondary lock 712 may help further secure the male terminal assembly 430 to the male housing assembly 220 and may reduce vibrational forces that are experienced by the male terminal assembly 430. In further embodiments, additional locking features may be utilized to lock the male terminal 430 within the male terminal housing 220.

The final step in assembling the male connector assembly 200 requires the assembler to couple the rear male housing 280 to the front male housing 224. As described above, the assembler will apply a connection force, F_(MC), on the rear male housing 280 to engage the connection means 222. Once the connection means 222 is engaged, the male housing assembly 220 is assembled; thus, finishing the assembly of the male connector assembly 200. It should be understood that all of the steps described above can be done in the reverse order to disassemble the male connector assembly 200. It should be understood that other structures, such as magnets, springs, alternative configurations of projections, alternative configurations of receivers, or a combination of these structures may be utilized.

Without being able to disconnect the male housing assembly 220 from the male terminal assembly 430, it would be difficult for the assembler to couple (e.g., weld) the wire 590 to the male terminal assembly 430 without potentially compromising the integrity of the male housing assembly 220. Nevertheless, there are alternative embodiments that allow void the need to be able to disassemble the male housing assembly 220. For example, the wire 590 or a stud (not shown) may be attached during the process of manufacturing the male connector assembly 200; thus, the assembler does not have to weld the male terminal assembly 430 to another structure (e.g., wire). In this example, the wire 590 may be coupled to the male terminal assembly 430 and then the housing may be formed around the male terminal assembly 430 using an injection molding or additive manufacturing process. In another example, the male housing assembly 220 may not need to be capable of being disassembled, if a different method (e.g., push in attachment method) of connecting the wire 590 to the male terminal assembly 430 was utilized.

FIGS. 1-2 and 13-46 a provide various views of the female connector assembly 600. The female connector assembly 600 includes: (i) a female housing 620, (ii) a female terminal 800, (iii) a female locking member 700, and (iv) a wire 890. Like the male housing assembly 220, the female housing 620 has complex geometry with a number of recesses and projections. In particular, the female housing 620 has a body 640 and a female CPA component 750. The body 640 also includes an arrangement of side walls 642 a-642 d that form a substantially rectangular receptacle 653, which is configured to receive the female terminal assembly 800 and the wire 890 (see FIGS. 15-16, 18, 21-22, 24-46 a). At least one of the side walls 642 a-642 d of the female housing 620 has means for displacing the contact arms 494 a-494 h during insertion of the male terminal 430. Referring specifically to FIGS. 31-32, the side walls 642 a-642 d of the female housing 620 an internal segment 651 designed to slidingly engage with an extent of the contact arms 494 a-494 h of the male terminal 430 during insertion of the male terminal assembly 200 into the receptacle 653 of the female housing 620, as detail below. The internal segment 651 is angled or sloped relative to the outer surface of the side walls 642 a-642 d at an internal angle, a. In this exemplary embodiment, the internal angle a is between 0.01 degrees and 15 degrees, preferably between 1 degree and 7 degrees and most preferably 5 degrees. Also, the internal angle α is substantially constant. This angled internal segment 651 is designed to gently compress contact arms 494 a-494 h inward as these two components slidingly engage while the operator (e.g., a worker or a robot) inserts the male connector assembly 200 into the receptacle 653 of the female connector assembly 600.

As best shown in FIG. 31, the angled internal segment 651 includes a leading, forwardmost extent 658 and a trailing, rearmost extent 654, which defines a length of the internal segment 651. The forwardmost extent 658 and the rearmost extent 654 are recessed from the leading edge 620 a of the female housing 620. The rearmost extent 654 is positioned adjacent to the forwardmost edge 818 of the female terminal 800, when the female terminal is received by the female housing receptacle 653. Also, as shown in FIG. 31 and due to its angled configuration, the angled internal segment 651 has a forward width 657 that extends between the forwardmost extent 658 of a first edge 660 a of the internal segment 651 and an opposing forwardmost extent 658 of a first edge 660 b of the internal segment 651. The forward width 657 is approximately 1% to 15% larger than a rear width 661 of the internal segment 651 that extends between a rearmost extent 654 of a first edge 662 a of the internal segment 651 and an opposing rearmost extent 654 of a first edge 662 b of the internal segment 651. In other words, the forward internal segment width 657 is greater than the rear internal segment width 661, which facilitates in the inward compression of the contact arms 494 a-494 h as the male connector assembly 200 is slidingly inserted into the female housing receptacle 653 of the female connector assembly 600.

Again referring to FIGS. 31 and 32, the rearmost extent 654 of the internal angled segment 651 is at least positioned coplanar with the inside surface 822 of the female terminal 800 and preferably positioned inward of the inside surface 822. Stated another way, the rear internal segment width 661 is smaller than a front receiver width 811 that extends between the forwardmost extent 818 of the inner surface 822 of one side wall 812 b and the opposed forwardmost extent 818 of the inner surface 822 of one side wall 812 d. In this exemplary embodiment, the rear width 661 may be 0.6 mm smaller than the receiver width 811.

It should be understood that in other embodiments, the sloped or angled configuration of the internal segment 651 may not be constant, may not be recessed from the leading edge of the housing 620 (see the Figures showing embodiment three), the dimensions may be different, and the internal segment 651 may not be continuous within the housing 620, instead, it may be discontinuous and thus only be present in certain locations. It should also be understood that the internal segment 651 is typically formed from the same material that the rest of the female housing is formed from, such as polymer (e.g., nylon or plastic). Utilizing a polymer material is beneficial because there is less friction between the metal contact arms 494 a-494 h and the polymer material in comparison to the friction between the metal contact arms 494 a-494 h and the metal female terminal 800. In alternative embodiments, a coating, liner or other materials may be used to line or coat the internal surface 652 to reduce the friction with the contact arms 494 a-494 h.

Two of the side walls 642 b, 642 d of the female housing 620 include a female locking means 643, which in this exemplary embodiment include a plurality of locking member projections 644 a, 644 b that are configured to interact with an extent of a locking member 700. The side walls 642 a, 642 b, 642 c also include a locking member opening 646. The locking member projections 644 a, 644 b and the locking member opening 646 are configured to interact with the female locking member 700 to secure the female terminal 800 within the female housing 620. Each of these locking member projections 644 a, 644 b, locking member opening 646, and other features of the female housing 620 will be discussed in greater detail in connection with FIGS. 15-46 a. It should be understood that the female locking means 643 may include a different arrangement, combination, or number of components. For example, the side walls 642 b, 642 d may include a recess that interacts with a projection that is formed on the female locking member 700. In even further embodiments, the female locking means 643 may include structures that using magnetic forces, spring forces, require partial rotation, or require full rotation forces or a combination of these forces.

FIGS. 2, 13-46 a depict various views of the female terminal 800. The female terminal 800 includes: (i) a female terminal body 810 and (ii) a female terminal connection plate 816. The connection plate 816 is directly connected to the female terminal body 810 and is configured to receive an extent of a structure (e.g., wire 890, as shown in FIG. 2) that connects the female terminal 800 to a structure (e.g., a radiator fan) outside of the connector system 100. The wire 890 is typically welded to the top connection plate 816 (shown in FIG. 2). However, other methods (e.g., forming the wire 890 as a part of the connection plate 816) of connecting the wire 890 to the connection plate 816 is contemplated by this disclosure.

The female terminal body 810 has a tubular configuration and is comprised of an arrangement of female terminal side walls 812 a-812 d that are coupled to one another to form a substantially rectangular shape. Specifically, one female terminal side wall 812 a of the arrangement of female terminal side walls 812 a-812 d is: (i) substantially parallel with another one female terminal side wall 812 c of the arrangement of female terminal side walls 812 a-812 d and (ii) substantially perpendicular to two female terminal side wall 812 b, 812 d of the arrangement of female terminal side walls 812 a-812 d. The female terminal body 810 defines a female terminal receiver 814. The female terminal receiver 814 is designed and configured to be coupled, both electrically and mechanically, to an extent of the male terminal 470, when the male terminal 470 is inserted into the female terminal receiver 814.

The female terminal 800 is typically formed for a single piece of material (e.g., metal). Therefore, the female terminal 800 is a one-piece female terminal 800 and has integrally formed features. In particular, the connection plate 816 is integrally formed with female terminal body 810 and specifically is integrally formed with the one female terminal side wall 812 c. To integrally form these features, the female terminal 800 is typically formed using a die cutting process. However, it should be understood that other types of forming the female terminal 800 may be utilized, such as casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the female terminal 800 may not be formed from one-piece or be integrally formed, but instead formed from separate pieces that are welded together.

FIGS. 13-29 show the positioning and the coupling of the female terminal 800 within the female housing 620. Coupling the female terminal 800 within the female housing 620 occurs across multiple steps or stages. The first step in this process starts with securing the female terminal 800 within the female housing 620 using a female securing means 647. The securing means 239 in this exemplary embodiment includes a female securing arm 648. A first insertion force, F_(I), causes the securing arms 648 to interact with a forwardmost extent 818 of the female terminal 800. This interact will cause the securing arms 648 to elastically deform outward and towards the side walls 642 b, 642 d. Specifically, the securing arms 648 will elastically deform into a securing arm gap 650. Positioning the securing arms 648 within the securing arm gap 650 will allow the female terminal 800 to be inserted into the female housing 620. It should be understood that the assembler must apply sufficient amount of insertion force, F_(I), to cause the securing arms 648 to elastically deform. Without apply this sufficient amount of insertion force, F_(I), the assembler will not be able to cause the securing arms 648 to elastically deform; thus, will not be able to position the female terminal 800 within the female housing 620. It further should be understood that the length of the securing arm 648, the thickness of the securing arm 648, and the material of the securing arm 648 will alter the amount of insertion force, F_(I), that is necessary to couple the female terminal 800 to the female housing 620.

The next step in the process of coupling of the female terminal 800 within the female housing 620 occurs when the assembler applies a second insertion force, F_(I), on the female terminal 800 to cause: (i) the forwardmost extent 818 of the female terminal 800 to be positioned against the rearmost extent 654 of the internal segment 651, (ii) the rearmost extent 820 of the female terminal 800 to be positioned against the securing arms 648. At this point, the securing arms 648 can return to their original or non-deformed state due to the fact the securing arm 648 can fit into a behind the rearmost extent 654 of the female terminal 800. The return of the securing arm 648 may cause an audible sound (e.g., click) when it moves from the deformed state to the non-deformed state. This audible sound will inform the assembler that the female terminal 800 is properly seated within the female housing 620; thus meeting industry standards and/or requirements (e.g., USCAR). Also, as shown in FIGS. 15-26, the female housing 620 can be properly seated within the female housing 620 while the female locking member 700 is only connected to the first locking member projection 644 a. This is because the female locking member 700 does not extend upward past the inner surface 656 of the side wall 642 c (see FIG. 20).

The final set in the process of coupling the female terminal 800 within the female housing 620 occurs when the assembler applies a locking force, F_(L), on the female locking member 700. The application of the locking force, F_(L), on the female locking member 700 will cause a first extent 710 of the male locking member 700 to elastically deform outward in order to overcome the female locking member projections 644 a, 644 b. Once the female locking member 700 has overcome the female locking member projections 644 a, 644 b, the first extent 710 of the female locking member 700 will return to its original or non-deformed state. The return of the first extent 710 of the female locking member 700 may cause an audible sound (e.g., click) when it moves from the deformed state to the non-deformed state. This audible sound will inform the assembler that the female locking member 700 is properly connected to the male housing 620; thus meeting industry standards and/or requirements (e.g., USCAR). Additionally, when the female locking member 700 is properly connected to the male housing 620, a secondary locking feature 712 is positioned behind the rearmost extent 820 of the female terminal 800. The securing arms 648 and the secondary locking feature 712 ensures that the female terminal 800 cannot be removed from the female housing 620 without damaging the housing 620. At this point, the female terminal 800 is properly coupled to male housing 620.

Without being able to disconnect the female housing 620 from the female terminal assembly 700, it would be difficult for the customer to couple (e.g., weld) the wire 890 to the female terminal 800 without potentially compromising the integrity of the male housing 620. Nevertheless, there are alternative embodiments that allow void the need to be able to disassemble the female housing 620. For example, the wire 890 or a stud (not shown) may be attached during the process of manufacturing the female connector assembly 600; thus, the assembler does not have to weld the female terminal 800 to another structure (e.g., wire). In this example, the wire 890 may be coupled to the female terminal 800 and then the housing 620 may be formed around the female terminal 800 using an injection molding or additive manufacturing process. In another example, the female housing 620 may be formed from multiple parts to enable the disassembly of the female housing 620. In other examples, the female housing 620 may have a different configuration if a different method (e.g., push in attachment method) of connecting the wire 890 to the female terminal 800 is utilized. The following disclosure describes one embodiment of how female terminal 800 may be inserted into and retained within the female housing 620. It should be understood that other structures, such as magnets, springs, alternative configurations of projections, alternative configurations of receivers, or a combination of these structures may be utilized. Examples of such configurations, as disclosed in connections within the other embodiments contained within this application.

FIGS. 30-46 a show the coupling of the male connector assembly 200 with the female connector assembly 600. Specifically, FIGS. 30-33 show the male connector assembly 200 disengaged from the female connector assembly 600. In other words, the connector assemblies 200, 600 are not electrically or mechanically coupled to one another. In this configuration or position, the connector assemblies 200, 600 are in a separated or disengaged position, P_(D). In the disengaged state, P_(D), devices that the connector system 100 is coupled thereto are typically not in operation. From the disengaged state, P_(D), the assembler applies a coupling force, F_(C), on the male connector assembly 200 to force the male connector assembly 200 towards the female connector assembly 600. This force cause the connector assemblies 200, 600 to move into an intermediate position, P_(I). In particular, this intermediate position, P_(I), is shown in FIGS. 33-35 and 39-41. In this intermediate position, P_(I): (i) the side walls 228 a, 228 c of the front male housing 224 are in contact with the side walls 642 b, 642 d of female housing 620 and (ii) the contact arms 494 a-949 h are placed in contact with the internal segment 651 of the female housing 620. However, in this intermediate position, P_(I), the male connector assembly 200 is not mechanically or electrically coupled to the female connector assembly 600.

From the intermediate position, P_(I), the assembler continues to apply a coupling force, F_(C), on the male connector assembly 200 to force the male connector assembly 200 towards the female connector assembly 600. This force causes the connector assemblies 200, 600 to move into a connected position, P_(C). In particular, this connected position, P_(C), is shown in FIGS. 37-38 and 43-46 a. Causing the connector assemblies 200, 600 to move from the intermediate position, P_(I), to connected position, P_(C), compresses the contact arms 494 a-494 h towards the center 490 of the male terminal 470 (compare FIGS. 34-35 with FIGS. 37-38). This inward compression of the contact arms 494 a-494 h in turn causes the spring arms 452 a-452 h to deform inward towards the center 490 of the male terminal 470. As discussed above, the spring member 440 resists this inward compression and applies an outwardly directed spring biasing force on the contact arms 494 a-494 h. In this connected position, P_(C), the male connector assembly 200 is mechanically and electrically coupled to the female connector assembly 600.

This configuration of the male connector assembly 200 and the female connector assembly 600 is beneficial over the connectors described in connection in PCT/US2018/019787 for the reasons described in the graph shown in FIG. 47. Specifically, the insertion force is graphed on the vertical axis and insertion distance is graphed on the horizontal axis. Also, the connector that is described in this application is shown by the solid line 950, while the connector that is described in PCT/US2018/019787 is shown in the dotted line 952. Lines for both connectors are equal between points 954 and 956 because these lines represent the connector moving from the disconnected position, P_(D), to the intermediate position, P_(I). At point 956, the insertion force for the connector disclosed herein starts to rise because the contact arms 494 a-494 h are being forced inward by internal segment 651. The insertion force for the connector disclosed within PCT/US2018/019787 does not start to rise at point 956 because the alternative configuration of the contact arms requires that the assembler insert the connecter a further distance before the contact arms come into contact with any structure contained within the connector. Therefore, at point 958, the insertion force for the connector disclosed within PCT/US2018/019787 finally starts to rise because the contact arms have come into contact with an internal structure of the connector. Based on this point alone, the connector system 100 described in this application is desirable over the connector system described within PCT/US2018/019787 because the distance the connector assemblies 200, 600 have to move before they move from the disconnected position, P_(D), to the intermediate position, P_(I), is less. In turn, this means that the connector system 100 described herein can be installed within a smaller space because it does not need this additional distance to form a connection.

Next, the lines 960 and 962 describe the insertion force that is required to move the connector from the intermediate position, P_(I), towards the connected position, P_(C). In particular, line 960 is associated with the connector described herein, while line 962 is the connector described within PCT/US2018/019787. The slope of the line 960 is less than the slope of the line 962. This means a more gradual amount of force is required by the connector assembles 200, 600 described herein in comparison to the connector assembly described within PCT/US2018/019787. This is because the contact arms 494 a-494 h described in this application are sliding along the polymer material surface of the internal segment 651, while the contact arms described within PCT/US2018/019787 are sliding along a metal surface. This is another benefit of the connector system 100 described herein over the connector system described within PCT/US2018/019787. In other words, the connector system 100 described herein can utilize a spring member 440 that has a larger biasing force while staying within the USCAR 25 specification in comparison to the connector system described within PCT/US2018/019787. This is beneficial because the use of a spring member that has a larger biasing force will ensure that the connector system 100 remains properly connected while receiving larger amounts of power.

Finally, after the contact arms 494 a-494 h described herein have cleared the rearmost edge 654 of the internal segment 651, the insertion force for the connection system 100 described herein levels off after point 964. This is because the contact arms 494 a-494 h, at this point, have been fully compressed and thus very little, if any, force is required to move the male terminal assembly 400 from the rearmost edge 654 of the internal segment 651 to the connected position. The leveling off of the insertion force at this point almost feels like the connector system 100 is pulling the male connector assembly 200 towards the female connector assembly 600. In contrast, the insertion force required for the connector system described within PCT/US2018/019787 only increases. This is because the contact arms described within PCT/US2018/019787 are not fully compressed until the male connector is coupled to the female connector. This is another benefit for why the connector system described herein is beneficial over the connector system described within PCT/US2018/019787.

FIGS. 39-46 a show the CPA assembly, which details how the extent of the male CPA component 352 interacts with the extent of the female CPA component 750 when the male connector assembly 200 moves from the intermediate position, P_(I), to the connected position, P_(C). The CPA connector assembly 350, 352, 750 allow the connector system 100 to meet certain industry standards and/or requirements, such as USCAR 12, USCAR-25, USCAR-2. Specifically, the elastically deformable CPA structure 354 elastically deforms downward, towards the wire 590, due to a forward wall 752 of the female CPA component 750. Once the connector system 100 is in the connected position, P_(C), (see FIGS. 42-44) a lateral bar 358 of the deformable CPA structure 354 is positioned passed the forward wall 752 of the female CPA component 750. This allows the deformable CPA structure 354 to return to its original or non-deformed state; thus, permitting the lateral bar 358 to be positioned within and adjacent to the innermost edge 754 of the forward wall 752. Finally, in the connected position, P_(C), the assembler applies an insertion force, F_(I), on the CPA component 350. This insertion force, F_(I), causes a forward projection 360 of the CPA component 350 to deform downward, towards the wire 590, in order to fit under the forward wall 752 of the female CPA component 750. Once the insertion force, F_(I), is sufficient to cause the forward projection 360 to be positioned past the lateral bar 358, the forward projection 360 can return to its original or non-deformed state. The return of the forward projection 360 may cause an audible sound (e.g., click) when it moves from the deformed state to the non-deformed state. This audible sound will inform the assembler that the CPA component 350 is properly seated; thus meeting industry standards and/or requirements (e.g., USCAR). The assembler can then apply a tug on the connector system 100 to ensure that the connector system 100 is properly coupled together. The assembler will apply similar forces in the reverse direction to disassemble the connector system 100.

It should be understood that the configuration of the CPA component 350, male CPA component 352 and the female CPA component 750 may help prevent the user from inadvertently connecting the male connector assembly 200 at an incorrect angle of rotation (e.g., 180 degrees). It should also be understood that the configuration of the CPA component 350, male CPA component 352, and the female CPA component 750 may include a different arrangement, combination, or number of components. For example, the combination of CPA component 350, male CPA component 352, and the female CPA component 750 may include structures that couple the CPA component 350 to an extent of the male CPA component 352 and the female CPA component 750 using magnetic forces, spring forces, require partial rotation, or require full rotation forces or a combination of these forces.

FIGS. 1, 36-38, 42-46 a, and 48-49 and discussed within PCT/US2019/036010, depict various views of the first embodiment of the male terminal assembly 430 within the female terminal 800. As shown in the Figures, the combination of outer surfaces of the contact arms 494 a-494 h form a rectangle that has a width/height that is slightly larger (e.g., between 0.1% and 15%) than the width/height of the rectangle that is associated with the female terminal receiver 800. When the slightly larger male terminal assembly 430 is inserted into the slightly smaller female terminal receiver 800, the outer surface of the contact arms 494 a-494 h are forced towards the center 490 of the male terminal assembly 430. Because the outer surface of the contact arms 494 a-494 h are forced towards the center 490 of the male terminal assembly 430, the free ends 446 of the spring member 440 a, 440 b are also forced towards the center 490 of the male terminal assembly 430. The spring 440 a, 440 b resists this inward displacement by providing a spring biasing force, S_(BF), (as depicted by the arrows labeled “S_(BF)” in FIG. 49). This spring biasing force, S_(BF), is generally directed outward against the free ends 488 of the male terminal 470. In other words, this spring biasing force, S_(BF), provides a wedging or shimmering effect against the contact arms 494 a-494 h thereby holding the outer surfaces of the contact arms 494 a-494 h in engagement with the female terminal 800.

The Figures show that the connector system 100 provides a connector that is 360° compliant, which meets the certain car or automotive specifications. As shown in this embodiment, the contact arms 494 a-494 h are symmetrical and evenly spaced. The connector system 100 is 360° compliant because the outer surface of the contact arms 494 a-494 h are in contact with each side wall 482 a-482 d of the female terminal 800 and the spring biasing force, SBF, applies out a force that is generally directed outward from the center 490 in all four primary directions (e.g., up, down, left, and right). The 360° compliance attribute of the connector system 100 aids in maintaining mechanical and electrical connection under strenuous mechanical conditions, e.g., vibration. In a traditional blade or fork-shaped connectors, i.e., connection on only two opposing sides, vibration may develop a harmonic resonance that causes the connector to oscillate with greater amplitude at specific frequencies. For example, subjecting a fork-shaped connector to harmonic resonance may cause the fork-shaped connector to open. Opening of the fork-shaped connector during electrical conduction is undesirable because momentary mechanical separation of the fork-shaped connector from an associated terminal may result in electrical arcing. Arcing may have significant negative effects on the terminal as well as the entire electrical system of which the terminal is a component. However, the 360° compliance feature of the present disclosure may prevent catastrophic failures caused by strong vibration and electrical arcing.

The male terminal 470, including the contact arms 494 a-494 h, may be formed from a first material such as copper, a highly-conductive copper alloy (e.g., C151 or C110), aluminum, and/or another suitable electrically conductive material. The first material preferably has an electrical conductivity of more than 80% of IACS (International Annealed Copper Standard, i.e., the empirically derived standard value for the electrical conductivity of commercially available copper). For example, C151 typically has 95% of the conductivity of standard, pure copper compliant with IACS. Likewise, C110 has a conductivity of 101% of IACS. In certain operating environments or technical applications, it may be preferable to select C151 because it has anti-corrosive properties desirable for high-stress and/or harsh weather applications. The first material for the male terminal 470 is C151 and is reported, per ASTM B747 standard, to have a modulus of elasticity (Young's modulus) of approximately 115-125 gigapascals (GPa) at room temperature and a coefficient of terminal expansion (CTE) of 17.6 ppm/degree Celsius (from 20-300 degrees Celsius) and 17.0 ppm/degree Celsius (from 20-200 degrees Celsius). The spring member 400 a, 400 b may be formed from a second material such as spring steel, stainless steel (e.g., 301SS, ¼ hard), and/or another suitable material having greater stiffness (e.g., as measured by Young's modulus) and resilience than the first material of the male terminal 470. The second material preferably has an electrical conductivity that is less than the electrical conductivity of the first material. The second material also has a Young's modulus that may be approximately 193 GPa at room temperature and a coefficient of terminal expansion (CTE) of approximately 17.8 ppm/degree Celsius (from 0-315 degrees Celsius) and 16.9 ppm/degree Celsius (from 0-100 degrees Celsius).

Based on the above exemplary embodiment, the Young's modulus and the CTE of the spring member 400 a, 400 b is greater than the Young's modulus and the CTE of the male terminal 470. Thus, when the male terminal 470 is used in a high power application that subjects the connector system 100 to repeated thermal cycling with elevated temperatures (e.g., approximately 150° Celsius) then: (i) the male terminal 470 become malleable and loses some mechanical resilience, i.e., the copper material in the male terminal 470 softens and (ii) the spring member 400 a, 400 b does not become as malleable or lose as much mechanical stiffness in comparison to the male terminal 470. Thus, when utilizing a spring member 440 a, 440 b that is mechanically cold forced into shape (e.g., utilizing a die forming process) and the spring member 440 a, 440 b is subjected to elevated temperatures, the spring member 440 a, 440 b will attempt to at least return to its uncompressed state, which occurs prior to insertion of the male terminals assembly 430 within the female terminal 800, and preferably to its original flat state, which occurs prior to the formation of the spring member 440 a, 440 b. In doing so, the spring member 400 a, 400 b will apply a generally outward directed thermal spring force, S_(TF), (as depicted by the arrows labeled “S_(TF)” in FIG. 49) on the free ends 488 of the male terminal 470. This thermal spring force, S_(TF), is dependent upon local temperature conditions, including high and/or low temperatures, in the environment where the system 100 is installed. Accordingly, the combination of the spring biasing force, S_(BF), and the thermal spring force, S_(TF), provides a resultant biasing force, S_(RBF), that ensures that the outer surface of the contact arms 494 a-494 h are forced into contact with the inner surface of the female terminal 800 when the male terminal 470 is inserted into the female terminal 800 and during operation of the system 100 to ensure an electrical and mechanical connection. Additionally, with repeated thermal cycling events, the male terminal assembly 430 will develop an increase in the outwardly directed resultant spring forces, S_(RBF), that are applied to the female terminal 800 during repeated operation of the system 100.

FIGS. 50-62 provide exemplary applications of the connector system 100 that can be used in a variety of vehicles and with a variety of vehicle components. In addition to these applications also include, but are not limited to, the following vehicle components: alternator, starter solenoid, motor (e.g., traction motor), starter generator, power electronics (e.g., inverter, power supply, battery charger), jumper cables, connections required for power cables, fuses, buss bars, grounds, relays, on board chargers, charging ports, cooling systems, high-power application, a high-current application, high-voltage applications, or any combination of these applications. Beyond these specific application, the connector system may generally be using within an airplane, the motor vehicle, a military vehicle (e.g., tank, personnel carrier, heavy-duty truck, and troop transporter), a bus, a locomotive, a tractor, a boat, a submarine, or in another other application where connector assemblies are essential to meet industry standards and production requirements.

FIGS. 50-53 provide a second application 4050 for the electrical connector system with an internal spring member 1440 b. The second or in-line fuse application 4050 is designed to be a complete in-line solution for providing an in line fuse. The in-line fuse 4050 includes: (i) a fuse 4052, (ii) two terminal connector systems 4054 that each have a male terminal assembly 4430 and a female terminal 4800, and (iii) exterior housing 4056. The terminal connector systems 4054 include a male terminal assembly 4430 and a female terminal 4800. General details about the design and functionality of the male terminal assembly 4430 and the female terminal 4800 are described above in connection with FIGS. 1-49, but additional detail about these specific terminal assemblies 4430, 4800 are described in greater detail in PCT Patent Application No. PCT/US2019/036070 at FIGS. 69-78. The in-line fuse 4050 also includes: (i) fuse holders 4058 that are configured to receive secure the fuse 4050 and the terminal connector systems 4054 within the external housing 4056, (ii) a CPA 4350, (iii) a cable strain relief 4530.

FIGS. 54-59 and 61 provide third application 4060 for the electrical connector system with an internal spring member 1440 b. The third or DC-DC power converter application 4060 is designed to be a complete solution for coupling the coupling a DC-DC power converter 4062 to another device (e.g., power source or power sink). The DC-DC power converter 4060 includes: (i) a DC-DC power converter 4062, and (ii) at least one terminal connector systems 4064 that have a male connector assembly 4200 and a female terminal 4600. General details about the design and functionality of the male connector assembly 4200 and the female terminal 4600 are described above in connection with FIGS. 1-49. Additional details about the male connector assembly 4200 and a female terminal 4600 shown in FIGS. 55, 57, 58 and 61 are described in greater detail in PCT Patent Application No. PCT/US2019/036070 at FIGS. 50-78. Further, additional detail about the terminal assemblies 4430, 4800 are described in greater detail in PCT Patent Application No. PCT/US2019/036010 at FIGS. 49-58. It should be understood that the terminal connection plates 4066 are interchangeable to meet the specific design requirements. For example, the first deign shown in FIG. 57 includes two separate terminal connector systems 4064, while FIG. 58 includes three separate terminal connector systems 4064, and FIG. 59 includes one terminal connector system 4064. Specifically, one terminal connector system 4064 may be used for a ground, a second terminal connector system may be used for 24 volts, and a third connector system may be used for 48 volts. Alternatively, each terminal connector system 4064 may have the same voltage and are simply powering different devices.

FIG. 60 provide fourth application 4080 for the electrical connector system with an internal spring member 1440 b. The fourth or battery pack application 4080 is designed to be a complete solution for coupling the battery pack contained within a vehicle to another device (e.g., power source or power sink). The battery pack 4080 includes: (i) a battery pack 4082, and (ii) a terminal connector systems 4084 that has a male connector assembly 4200 and a female terminal 4600. General details about the design and functionality of the male connector assembly 4200 and the female terminal 4600 are described above in connection with FIGS. 1-49. Additional details about the male connector assembly 4200 and a female terminal 4600 are described in greater detail in PCT Patent Application No. PCT/US2019/036070 at FIGS. 50-78. Further, additional detail about the terminal assemblies 4430, 4800 are described in greater detail in PCT Patent Application No. PCT/US2019/036010 at FIGS. 49-58. In particular, the terminal connector systems 4084 is designed to directly replace the connector 4084 shown on the battery pack 4082 without modification.

FIG. 62 provide fifth application 4090 for the electrical connector system with an internal spring member 1440 b. The fifth or fuse box application 4090 is designed to be a complete solution that can replace a fuse box in a vehicle. The fuse box 4090 includes: (i) a housing 4092, and (ii) at least one terminal connector systems 4094 that has a male connector assembly 4200 and a female terminal 4600. General details about the design and functionality of the male connector assembly 4200 and the female terminal 4600 are described above in connection with FIGS. 1-49. Additional details about the male connector assembly 4200 and a female terminal 4600 are described in greater detail in U.S. Provisional Patent Application No. 62/681,973 and within PCT Patent Application No. PCT/US2019/036070 at FIGS. 1-49. Further, additional details about the terminal assemblies 4430, 4800 are described in greater detail in PCT Patent Application No. PCT/US2019/036010 at FIGS. 49-58. In addition to distributing power using terminal connector systems 4094, this fuse box 4090 also utilizes a male terminal assembly 4430 a to receive power from a device (e.g., battery pack). Additional details about this terminal are described in greater detail in PCT Patent Application No. PCT/US2019/036010 at FIGS. 39-48. Generally, it should be understood that the designer may selectively utilize various embodiments of the connector assemblies 4430, 4800 shown in PCT Patent Application No. PCT/US2019/036010 to meet the desired power requirements of the fuse box 4090. For example, the designer may select the connector assembly 4430, 4800 shown in FIGS. 1-38 to meet a 200 amp requirement, while using the connector assembly 4430, 4800 shown in FIGS. 69-78 to meet a 30 amp requirement. The ability to selectively utilize different connector assemblies 4430, 4800 in connection with different devices is beneficial because it saves installation time, space, materials, weight and reduces failures.

FIG. 63 provides a simplified electrical diagram of a motor vehicle 500 that includes multiple connector systems. The motor vehicle 5000 includes: (i) a first connector system 5001 that is connected between an AC/DC converter 1 and a second connector system 5003 that is connected to a power distribution box 4, wherein the first and second connector system 5001, 5003 connect the AC/DC converter 1 to the power distribution box 4, (ii) a third connector system 5002 that is connected to the power distribution box 4 and a fourth connector system 5004 that is connected to electrical supercharger 9, wherein the third and fourth connector systems 5003, 5004 connect the power distribution box 4 to the electrical supercharger 9, (iii) a fifth connector system 5005 that is connected to 48 volt battery and a power distribution box 4, (iv) a sixth connector system 5006 that is connected to a second power distribution box 4 and (v) a seventh connector system 5007 that is also connected to the second power distribution box 4.

Materials and Disclosure That are Incorporated by Reference

PCT Patent Application No. PCT/US2019/036010, filed on Jun. 7, 2019, PCT Patent Application No. PCT/US2019/036070, filed on Jun. 7, 2019, and PCT Patent Application No. PCT/US2018/019787, filed on Feb. 26, 2018, each of which are fully incorporated herein by reference and made a part hereof.

SAE Specifications, including J1742_201003 entitled, “Connections for High Voltage On-Board Vehicle Electrical Wiring Harnesses—Test Methods and General Performance Requirements,” last revised in March 2010 and which is fully incorporated herein by reference and made a part hereof.

DIN Specification, including Connectors for electronic equipment—Tests and measurements—Part 5-2: Current-carrying capacity tests; Test 5b: Current-temperature derating (IEC 60512-5-2:2002), which is fully incorporated herein by reference and made a part hereof.

USCAR Specifications, including: (i) SAE/USCAR-2, Revision 6, which was least revised in February 2013 and has ISBN: 978-0-7680-7998-2, (ii) SAE/USCAR-12, Revision 5, which was last revised in August 2017 and has ISBN: 978-0-7680-8446-7, (iii) SAE/USCAR-21, Revision 3, which was last revised in December 2014, (iv) SAE/USCAR-25, Revision 3, which was revised on March 2016 and has ISBN: 978-0-7680-8319-4, (v) SAE/USCAR-37, which was revised on August 2008 and has ISBN: 978-0-7680-2098-4, (vi) SAE/USCAR-38, Revision 1, which was revised on May 2016 and has ISBN: 978-0-7680-8350-7, each of which are fully incorporated herein by reference and made a part hereof.

INDUSTRIAL APPLICABILITY AND DEFINITIONS

The above disclosure may represent an improvement in the art because it improves the mechanical and electrical connection between a male connector assembly and a female connector assembly. Such a connector assembly may be used in high-power and/or high-voltage conditions that may be found in the automotive industry or other applications (e.g., military equipment, space flight, electric vehicles, industrial machinery, etc.). It should be understood that the following terms used herein shall generally mean the following. “High power” shall mean: (i) between 20 volts to 600 volts regardless of the current or (ii) at any current greater than or equal to 80 amps regardless of the voltage. “High current” shall mean current greater than or equal to 80 amps regardless of the voltage. “High voltage” shall mean between 20 volts to 600 volts regardless of the current. “Substantially” shall mean essentially or without material deviation, which is in some instances is less than a 10 percent deviation from normal.

While some implementations have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the disclosure; and the scope of protection is only limited by the scope of the accompanying claims. For example, the overall shape of the connector assembly 100 may be changed to: a triangular prism, a pentagonal prism, a hexagonal prism, octagonal prism, sphere, a cone, a tetrahedron, a cuboid, a dodecahedron, a icosahedron, a octahedron, a ellipsoid, or any other similar shape. While the overall shape of the connector assembly 100 may be altered, the shape of the male terminal assembly 430 and the female terminal 800 may not be altered to match the shape of the overall connector assembly 100. For example, the shape of the connector assembly 10 may be a hexagonal prism, while the male terminal assembly 430 and the female terminal 800 may be substantially cubic. In other embodiments, the shape of the male terminal assembly 430 may be changed to: a triangular prism, a pentagonal prism, a hexagonal prism, octagonal prism, sphere, a cone, a tetrahedron, a dodecahedron, a icosahedron, a octahedron, a ellipsoid, or any other similar shape. If the shape of the male terminal assembly 430 is altered to be any one of the above shapes, then it should be understood that the female terminal 800 may be altered to facilitate insertion, electrical connection, and extraction of the male terminal assembly 430 from the female terminal 800. Additionally, as described above, while the shape of the male terminal assembly 430 and the female terminal 800 may be altered, the overall shape of the connector assembly 10 may not be altered to match the shape of the male terminal assembly 430.

In other embodiments, one or both of the rear spring wall 444 may be omitted. The spring member 440 a, 440 b may have a different configuration, such as: (i) having curvilinear shoulder disposed near the free end 446, (ii) having a wall that is positioned opposite of the rear wall and is connected to an extent of one of the spring fingers in order to limit movement of the free end 446, (iii) the width of the spring arms may be greater than the width of the middle sections, (iv) the width of the spring fingers may not match the width of the contact arms (e.g., spring fingers may be wider or narrower than the contact arms), (v) or any combination of these features.

In other embodiments, the male terminal body 472 may have a different configuration, such as: (i) the contact openings may not be linear (e.g. curvilinear), may be different lengths, may have different widths, may extend past where the contact arms intersect the side walls or may not span the entire length of each contact arm, (ii) the contact arms may not extent from the side walls at an outward angle, (iii) not gap may not be formed between the spring member and the contact arms, (iv) may be comprised of different materials (e.g., c151 is plated with (a) silver, (b) tin, (c) ss301, (d) other similar materials, or (e) a combination of a plurality of these materials).

Headings and subheadings, if any, are used for convenience only and are not limiting. The word exemplary is used to mean serving as an example or illustration. To the extent that the term include, have, or the like is used, such term is intended to be inclusive in a manner similar to the term comprise as comprise is interpreted when employed as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. It should be understood that the term substantially shall mean essentially or without material deviation, which is typically less than a 10° deviation.

Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.

Numerous modifications to the present disclosure will be apparent to those skilled in the art in view of the foregoing description. Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the disclosure. 

1. An electrical connector system for electrically and mechanically connecting with a component in a motor vehicle, the electrical connector system comprising: a motor vehicle component; a male connector assembly mechanically and electrically connectable to the motor vehicle component, the male connector assembly including: (i) a male terminal having an arrangement of side walls defining a receiver, each side wall having a U-shaped configuration with an intermediate segment adjacent an aperture formed in the side wall, and wherein the male terminal also include a contact arm that extends from said intermediate segment and across an extent of the aperture; (ii) a male housing having an arrangement of side walls, wherein each side wall has an aperture configured to receive an extent of the contact arm to expose said extent of the contact arm; (iii) an internal spring member having a base and a spring arm that extends from the base, the spring member dimensioned to reside within the receiver of the male terminal to define a partially assembled state of the male connector assembly; a female connector assembly mechanically and electrically connectable to the motor vehicle component, the female connector assembly including: (i) a female terminal with a receptacle dimensioned to receive both the male terminal and the spring member residing within the receiver of the male connector in the partially assembled state; (ii) a female housing having an arrangement of side walls defining a receptacle that receives the female terminal and an extent of the male connector assembly, and wherein at least one of the side walls includes an angled internal segment; wherein, when the connector system moves from the partially assembled state to a connected position to electrically and mechanically connect with the vehicle component, (a) the male connector assembly is inserted into the receptacle of the female housing, (b) the contact arm of the male terminal is brought into sliding engagement with the angled internal segment of the female housing, and (c) the contact arm is inwardly displaced as the contact arm slidingly engages with the angled internal segment.
 2. The electrical connector system of claim 1, wherein the female connector assembly is integrated into a busbar.
 3. The electrical connector system of claim 1, wherein the male terminal includes a plurality of contact arms and the spring member includes a plurality of spring arms, and wherein in the connected position (i) a first spring arm exerts a first outwardly directed biasing force on a first contact arm to displace the first contact arm into engagement with the inner surface of the receptacle, and (ii) a second spring arm exerts a second outwardly directed force on a second contact arm to displace the second contact arm into engagement with said inner receptacle surface, and, wherein the first outwardly directed biasing force is oriented in a different direction than the second outwardly directed biasing force.
 4. The electrical connector system of claim 1, wherein the first material of the male terminal is a highly conductive copper including at least one of the copper alloys commonly designated C151 or C110.
 5. The electrical connector system of claim 1, wherein the second material of the spring member is spring steel.
 6. The electrical connector system of claim 1, wherein the U-shaped side wall of the male terminal further includes a pair of opposed end segments that extend from opposite ends of the intermediate segment, wherein the end and intermediate linear segments collectively define the aperture in the side wall.
 7. The electrical connector system of claim 1, wherein the contact arm includes a free end opposite the intermediate segment, and wherein the outwardly directed force exerted by the spring arm is applied at the free end of the contact arm.
 8. The electrical connector system of claim 7, wherein the free end of the contact arm is engaged by a substantially planar outer surface of the spring arm when the outwardly directed biasing force is applied by the spring arm.
 9. The electrical connector system of claim 1, wherein the male terminal includes a moveable front wall that encloses the receiver and the spring member when the spring member is positioned within said receiver to arrive at a fully assembled state of the male connector assembly.
 10. The electrical connector system of claim 1, wherein the outwardly directed thermal force applied by the spring arm on the contact arm in the connected position is increased by residual material memory and thermal expansion due to elevated temperatures experienced during use of the electrical connector assembly.
 11. The electrical connector system of claim 1, wherein the side wall arrangement of the male terminal comprises two opposed side walls that define an outer side wall height of less than 7.0 mm, and wherein the electrical connector assembly can transfer 100 amps of current from the power source to the component while meeting the applicable USCAR specifications for automobiles.
 12. The electrical connector system of claim 1, wherein the angled internal segment is an angled surface formed along an inner surface of the receptacle of the female housing.
 13. The electrical connector system of claim 12, wherein the angled surface of the angled internal segment is continuously formed along an inner surface of the receptacle of the female housing.
 14. The electrical connector system of claim 1, wherein the angled internal segment is formed a distance from a leading edge of the female housing.
 15. The electrical connector system of claim 1, wherein due to its angled configuration the angled internal segment has a reduced width from its leading edge to its trailing edge.
 16. The electrical connector system of claim 1, wherein the electrical connector system further comprises a connector position assurance assembly that meets USCAR Specifications.
 17. The electrical connector system of claim 16, wherein the connector system is in an intermediate position when the contact arm of the male terminal is initially brought into sliding engagement with the angled internal segment of the female housing.
 18. The electrical connector system of claim 17, wherein the connector position assurance assembly includes: a male connector position assurance component that includes an elastically deformable structure and a substantially non-deformable structure; a female connector position assurance component that includes a substantially non-deformable structure that has a forward wall; a connector position assurance component, wherein, as the connector system moves from the intermediate position to the connected position, the elastically deformable structure is temporally inwardly displaced as the elastically deformable structure engages with the forward wall of the female connector position assurance component.
 19. The electrical connector system of claim 18, wherein when the connector system is in the connected position, the elastically deformable structure is positioned within the forward wall of the female connector position assurance component.
 20. The electrical connector system of claim 19, wherein when the connector system is in the connected position, the connector position assurance component can be inserted into an extent of the female connector position assurance component to secure the elastically deformable structure inside of the forward wall of the female connector position assurance component.
 20. The electrical connector system of claim 1, wherein the motor vehicle component is a battery.
 21. The electrical connector system of claim 1, wherein the motor vehicle component is an alternator.
 22. The electrical connector system of claim 1, wherein the motor vehicle component is an inline fuse assembly.
 23. The electrical connector system of claim 1, wherein the motor vehicle component is a DC-DC converter assembly.
 24. The electrical connector system of claim 1, wherein the motor vehicle component is a power distribution assembly converter assembly.
 25. The electrical connector system of claim 1, wherein the motor vehicle component is an auxiliary electric motor. 